Windshield, Replacing

Windshield, replacing

Special tools:
951 2925 Rollout 2000 951 2925 Rollout 2000
998 6030 998 6030

As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information in the illustrations is always correct.

Removing the windshield




Remove the windshield wiper arms.

Hint: If the wiper arm is tight, slacken off the nut. Then remove the wiper arm using pliers (see illustration), or use a puller.

Remove the plenum chamber.




Cut the wire.




Bend the ends to make it easier to pull in.




Pull in both the wire ends for the sun visor.




Have tape ready to secure the wire.
Feed down the wire up at the roof.
At the A-post, the wire will usually drop down itself when it is stretched.




Feed down the wire and secure with tape.
At each corner the wire must be stretched so that it presses down against the adhesive.




Pull in the excess wire towards the right-hand A-post.




There are three spacers in the bottom edge of the glass.




Guide the wire up towards the windshield at the spacers by pressing one or more nails (or an electricians screwdriver) against the spacers in the adhesive.




Secure a winch on the windshield.




Secure the long wire to the winch.





Note! Protect the dashboard and panels using a plastic disc or similar.




Begin winching in the wire.

Warning! Use protective goggles.




Release the winch from the windshield. Pull out the lug (1) and move the winch.

Note! Hold the roll secure by hand so that the wire does not spin off.




Keep an eye on the other wire end to ensure that it does not move.




Secure the winch (2).




Ensure that the wire does not catch anywhere.






Installing windshields

Note! Always open a side window when replacing the windshield, otherwise the windshield may move when the door is closed.

When working with PUR on the body flange, see PUR on body flange .
Place the windshield on the stand.
Install the suction pads, special tool 998 6030 998 6030.




Clean the area on the windshield to which PUR adhesive is to be applied. Use cleaner-H (black cap).




Apply glass activator (yellow cap) to the area on the windshield to which PUR adhesive will be applied.




Apply glass primer (green cap) to the area on the glass to which PUR adhesive will be applied.
Apply generously (although not so much that it runs).
Let the glass primer dry until the surface is matte.
Apply PUR rim activator (blue cork) to the remaining PUR bead on the body flange if the PUR bead has been exposed for more than eight hours.





2 component:
Load the gun with both cartridges and the mixing pipe.
Use the blue nozzle if supplied.
If there is no blue nozzle, use the intact (unmodified) nozzle. Measure 55 mm up from the base. Cut off the nozzle. Drill a 3 mm hole 36.5 mm from the tip. Measure 8 mm up at the tip. Cut off the nozzle. This makes a nozzle which gives a PUR-bead with a height of 18 mm and a base of 8 mm. This height is only required for fully cleaned bodywork.
If there is residual PUR bead on the body flange, increase the application speed to achieve a lower bead.
Attach the nozzle.
Apply adhesive to either the glass or to the body flange.
Hold the gun at right angles.
Ensure that the bead is continuous, otherwise the join will not be watertight.
Position the glass.
Check that the windshield is in the same position at both A-posts.
Push against the lower edge of the windshield by hand so that it comes down to the lower spacers.
Place a few strips of masking tape on the glass and part way over the roof to prevent the glass from sliding down.

Install:
- the windshield wiper arms
- the plenum chamber.